Failure Analysis & Prevention

Dr. Dheerendra Kumar Dwivedi

Department of Mechanical and Industrial Engineering
Indian Institute of Technology, Roorkee

Lecture - 05
Fundamental Sources of Failures: Deficient Design III and Upgrading of a part

Hello, I welcome you all in this presentation related with the subject failure analysis and
prevention. And we are talking about the fundamental sources of the failure, under the
failure analysis and prevention subject. We have talked about the two aspects related
with the deficient design, and these were there in form of the presence of the stress
raisers.

(Refer Slide Time: 00:47)

And the second one, about which we have talked, was about the imperfections in base
metal.

We will be talking about the few other aspects related with the deficient design. And
these may be in form of upgrading of a part or system; which had a very successful
record of the performance to the some more severe conditions for different application.
So, upgrading of a part with good record of service to a new application; this is one thing
or to the more severe service conditions.
So, sometimes we are encouraged so much with the very good performance of some of
the systems or the mechanical components that they are also recommended for the
different application for the different service conditions. So, which sometimes leads to
the premature failure of the component and the reason for this kind of the failure
becomes it may be in the variety of forms.

For that we can see that the deficiency it is in design of a component can be in various
forms like presence of a stress raisers changing design without proper consideration,
duplicating a success full design for more severe loading conditions. About this aspect
we are going to talk. There is another aspect related with the deficient design about
which we will be talking in this presentation is, designed developed without full
knowledge of the stress conditions due to inability to calculate the stress is properly, or
due to the complexity of the geometry of the component which is to be designed, or
inability to use the proper criteria for the designing.

(Refer Slide Time: 03:05)

So, under the first one where we have to consider upgrading of a part to the more severe
conditions. This can lead to the failure of the component due to arrange of the conditions.
One is like the metal is unsuitable for a given application.
(Refer Slide Time: 03:47)

Unsuitability of metal for new application; So, this is one this way unsuitability maybe in
form of more severe wear conditions or more severe temperature conditions; like,
something had a good record for the room temperature conditions. If the same is used
either for low temperature conditions like, minus 20 degree centigrade or high
temperature conditions like 300 degree centigrade.

So, the performance of the component may not be the same. Similarly, something had
very good record for performance under the normal ambient conditions. Normal ambient
conditions, but if the same is placed under the conditions like seawater conditions; where
both corrosion and erosion is severe or some petrochemical industry or some like in
chemical industry, where the corrosion is dominating.

So, the performance may be very adversely affected. Because the material which had
very good record of the performance under the normal ambient condition may not be
able to perform in the same way, under the different service conditions, for which it has
not been it does not have the required characteristic. So, it is a so, it is not necessary that
a product which is having a very good record of the performance, we will also form we
will also be showing the similar kind of performance for the newer applications.

So, this is what we can see here unsuitable metal of the component for the new
applications may be in form of high or low temperature kind of or we are corrosion or
the mechanical performance.
(Refer Slide Time: 05:38)

Like, for one application where the toughness may not be important, at room
temperature, but the toughness becomes crucial at the low temperature conditions is the
same is to be used.

(Refer Slide Time: 06:00)

Now coming to another point like the heat treatment requirements; especially this is true
for the steels which are subjected to the heat treatment like the quenching and tempering.
So, quenching is done primarily for the hardening purpose and tempering is done to
induce the required toughness. So, the combination of the strength and toughness can be
realized, and this will be this properties will be corresponding to the particular
temperature of the tempering.

So, say steel is tempered at 400 degree centigrade. And the steel which had which was
quencher quenched and tempered at 400 degree centigrade had very good performance
record. But if the same component is to be used under the temperature conditions of the
450 degree centigrade during the service, then it will be during the service itself will be it
will be over tempered.

And that will be leading to the degradation in properties of the steel softening of this
steel and which may get rid the mechanical performance. And so, premature failure of
the component can take place. So, this is one typical example where the improper heat
treatment of the component, the composition may be suitable, but the if the heat
treatment is inappropriate for newer application, then it also can lead to the a failure.
similarly are the stress relieving if in one situation is stress relieving may not be crucial.

But for new application if the stress concentration, if the loading conditions are more
severe; than inappropriate stress relieving can also lead to the premature failure of the
component. Then there maybe size and shape requirements.

(Refer Slide Time: 07:38)

Size and shape requirement for the new service conditions are for new application. Like,
if earlier it was being used for carrying the load of the 150-kilo Newton, but in the new
service if it is to be subjected to the 200-kilo Newton, then it will be experiencing the
more severe stress conditions. So, the no change out the geometrical features which were
present in the component; might not have been that up crucial, but under the sea more
severe stress conditions these no change and the stress raisers may become very crucial.

So, the similar so, in that in that case, the no chase and the geometrical features may
required the different kind of the geometries and the locations; in order to avoid their
adverse effect on the performance. So, the size and shape requirements may be different
for the newer service conditions. And if without doing that without changing the size and
shape for newer service where loading conditions are different, then also it can lead to
the premature failure of the component. Similarly, then we have the complex stress field
become crucial for the newer stress concentration. sometimes like if the component was
being subjected to the tensile stresses. And in the newer application, it finds that it is
being subjected to the torsional stresses.

So, tensile stresses are uniformly distributed across the cross section ah, but in case of
the torsional loading conditions the maximum stresses are found at the surface. So, the
discontinuity is which are present at the surface may be more crucial for the torsional
loading, and for the bending conditions as compared to the case when it is a simple
stresses magnitude is uniform across the section. So, here while in case of the torsion, the
stresses, and in the core or near the center is 0, or it is very less as compared to the case,
when tensile stresses, in case of tensile stresses they are uniform across the section.
(Refer Slide Time: 09:39)

So, depending upon the type of stresses severity of the stresses or complexity of stresses,
that different sizes and shapes may a play a crucial role. So, the complex stress
conditions for the newer application may also lead to the failure.

(Refer Slide Time: 10:12)

So, the point is about complex stress field may be crucial for the new application, for
new application. Then there is another point like the presence of stress raisers which
were not that important, but these may be very crucial under the newer conditions
because of the complex stress field or the more sever loading conditions. So, they need to
be considered differently. Say for example, if there was a notcher with the radius of like
say 0.5 mm.

(Refer Slide Time: 10:53)

So, this will be causing the more severe stress conditions as compared to the case, when
it had like say 1.5. So, under the low load conditions like 150-kilo Newton, it may be ok;
But if the load magnitude is increased to the 250-kilo Newton then these stress raisers
may become more crucial and that case it may require the different, radius at the cractive
for avoiding the necessity too high stress concentration; so that the premature failure of
the component can be avoided.

So, presence of stress raisers can be critical, for more sever conditions as compared to
the earlier service conditions. Now in light of these points will be taking of one case is
study where the engineers encouraged with the very long and successful performance of
the spring inner cap for the automobile; which we can see here in this diagram.
(Refer Slide Time: 12:06)

What this diagram shows? This is the spring which is used in case of opening and closing
of the walls in IC engines. And this is spring is retained with the help of this cap. So, this
is the stress string retainer cap and this cap with the cross section of this cap can be seen
how this is the upper portion and these are the different levels in the cap which are used
to accommodate this springs.

So, spring remains under the spring will keep on. The retainer will always be under the
loading due to the spring. And in this case, we can see there are some junctions, warren
cross sections and at the cross sections some the fillets are there. So, these fillets will be
used for having the gradual change in the loading and gradual change in the stress
distribution. So, ah, but in this particular case, the retainer cap for the retainer cap was
which was which had a very good record of the performance.

Retainer cap which had a very good record of the performance for the low capacity
engine like say 4-cylinder engine, but when it was a used with a 8-cylinder automobile,
during the qualification run itself the retainer cap failed. So, retainer cap failed during the
field trails or the qualification run often a 8-cylinder automobile, and the cap broke
before trail run of 1200 or 200 hours at 4000 rpm to the 4600 rpm after 26 million cycles.
So, this test simulates continues running of the engine for 200 hours at one 40 miles per
hour.
And so, these were the service conditions this the retainer cap field, and the cap was
made of the made from the 16 mm cold drawn 101, this is the plain carbon steel having
the 0.1 percent. Carbon was made of the 101-carbon steel, this is AIS designation of the
steel, and it was in an yield condition. So, the processes watch which were used for
making the retainer cap over the forging and then trimming followed by case hardening
using the carbo nitriding for 30 minutes at 843 and the oil quenching for the hardening
purpose. And in order to induce the desired toughness and to avoid unnecessary
development of the residual stresses tampering was done at 260 degree centigrade.

So, are through this case hardening heat treatment the case depth was a it was desired to
harden the case up to the depth of 0.0 up to the depth of in a range of 0.05 to 0.25 mm so,
as to achieve the hardness of 86 HRB. So, the macro is copy of the broken cap showed
that showed that the fracture actually originated from the section where, changing cross
section was taking place.

(Refer Slide Time: 15:40)

And which we can see here, this is the periphery along which the cross section, change in
cross section was taken taking place. And this and this arrowed zone showed arrowed,
this arrow shows the location where from it was triggered, a smooth region at in this area
shows the nucleation of the crack by the fatigue. And there after it has grown in this
direction. And then sudden fracture zone is rugged rough and irregular. So, all this area is
corresponding to the sudden fracture zone, and a smooth zone shows the location where
the crack propagated in fatigue manner.

So, a smooth area on fracture surface is characteristic of the fatigue fracture with the
brightness at the arrow zone shows the location where from crack initiated regular
rugged areas correspond to correspond to the final fracture. And there was no sign of the
plastic deformation; which suggests that material had a good in strength, but the crack
nucleated in the high stress areas, and then it grown under it grew under the influence of
the fatigue loading, and then it failed catastrophically. Metallography also suggested the
normal the ferritic and paralytic structure with the dominance of the ferrite. So, the
microscopy also did not show any issue related with the microstructure.

So, to confirm whether the cap had required properties or not, chemical analysis was
performed. And chemical analysis of the cap showed that it is the composition of the cap
is corresponding to the AISI 101 with the percentage of the carbon 0.11.

(Refer Slide Time: 18:36)

And the manganese percentage 0.48, and the microscopy of the case-hardened depth
showed that it was have 0.2 mm, and the mic and the hardness was found in the range of
84, which is slightly below than the specified value of the 86 HRB. And the
microstructure because the; because it was of the low carbon steel. So, it had a normal
paralytic structure as expected without any inclusion and the other abnormalities. So, this
analysis showed that the fracture initiated and propagated by the fatigue. And before
final fracture, the crack growled at the crack grew at the junction where cross change in
cross section was taking place.

So, the crack nucleated at the fillet between the pilot and the flange and now significant
material and manufacturing problem was found. So, in order to overcome this issue
because the location suggested; that the crack nucleated and it grew from the fillet zone.
So, obviously, it was indicating that high stress concentration due to the some (Refer
Time: 18:59) fillet led to the nuclear nucleation and growth of the crack under the fatigue
conditions easily.

And that is why design of the cap fillet radius was increased from 0.5 to 1.5 mm. For
better stress distribution, which in turn increases the fillet and this increased fillet radius
also helped in the manufacturing. Because it is more difficult to read to realize or to
achieve the find radius as compared to the bigger radius. And this correction led to the
successful performance of the retainer cap subsequently. Now we will be talking about
the other aspects related with the deficiency in design.

So, this one about which we have talked like upgrading of part upgrading of parts of a
part to new application for which, in this particular case in appropriate fillet radius led to
the failure.

(Refer Slide Time: 19:54)

There can be number of reasons for the failure when a part is upgraded to the new
application because the part is not designed for that application. Now the second aspect
is that the design criteria, you see whenever the opponent is designed, the design of a
part or component for an application. So, whenever the design is made what we consider
we consider the service conditions, which for the mechanical design are primarily in
terms of the load. Like that type of the load magnitude of the load and service
environment like in form of the temperature or corrosion.

So, all these need to be considered when we are talking about the a design to be
developed for a given applications, but many times due to the improper calculation of the
improper stresses for the design purpose, means the if the design is based on the if the
design is based on the improper stress criteria. Then it can lead to the failure and we now
we try to find out the service conditions effectively.

So, that we are aware of the type of the load the type load in terms of the type of load
magnitude and the service conditions. But sometimes we find it really difficult to have
the kind of a stresses which are to be used properly. And this is can arise due to the two
types of situations; in that improper is stresses are being used for the design purpose, this
can arise from the two causes. One is incorrect estimation of the load.

(Refer Slide Time: 22:13)

So, basically component parts machine systems we used as an earth moving must seems
or that excavate or, the mining equipments which are which can be subject to the varying
load conditions. So, in those conditions becomes really very difficult to correctly
estimate the kind of load which will be acting during the service. So, incorrect estimation
of the load during the service, and it is that type and magnitude. All these can be leading
to the improper stress criteria or the improper stresses during used for the design
purpose. And sometimes it becomes difficult to calculate inability to calculate the
stresses which will be acting on the component.

So, sometimes the geometries of few components are so complex, that they make it
difficult to properly determine the, calculate the kind of a stresses, which will be acting
on to the component. So, improper estimation of the load and inability to calculate the
stresses accurately for a given service conditions due the complexity of the geometry of
the component.

So, these are these two situations will be leading to the use of improper a stress. And if
the design is based on the incorrect stresses, then of course, it will provide the easy
source for the failure of the component. Because the section size and the shape of the
component all those will not be proper. So, under a continuing with this one, if we really
do not know what kind of the service conditions are there we are not able to estimate the
load properly, and we are not able to calculate the stresses properly, then this can lead to
the improper design of the component. So, apart from the improper design of the
component, there can be another issue like, whatever the metal is being selected, metal
selection for a given application.
(Refer Slide Time: 24:55)

So, in on what basis the material should be selected? For the given application we know
that, each metal will have certain mechanical physical properties. Like say, the metal A
maybe of the high sigma y value and the low percentage elongation. And the metal B
maybe a very low sigma y value, but the high percentage elongation.

So, and likewise there can be very wide ranges. Like, the titanium alloys may have the
strength of 1800 ampere; on the other hand, our simple mild steel may have like say 350
to 500 ampere. So, there can be lot of variation in terms of the extent that they offer in
terms of the toughness and ductility that they offer. So, what we should consider for the
designs purpose? On what bases are given material should be selected? And for that
purpose, basically, we need to consider the expected failure mechanism. You know the,
whatever component will be made that will put into the use.

So, during the application according to the service conditions, we need to estimate we
need to predict we need to identify in which way the component can fail. The failure of
components say can occur due to the ductile fracture brittle fracture ductile fracture,
where lot of elongation and deformation will be taking place brittle fracture where
without any change in cross section or change in the size, and shape of the components
suddenly the fracture will be taking place, or the component will be subjected to the high
temperature.
So, the change in dimensions will be taking place due to the creep or the component will
subject to the fluctuating loads. So, here it will subjected to the fatigue or the component
will be put into subject the use this component will subjected to the corrosion. So,
likewise there can be different situations, there can be v r variety of firms like abrasion,
erosion, capitation etcetera. So, there can be variety of ways by which the failure of
metal can take place during the service.

So, that failure mechanism expected failure mechanism is to be identified. And

accordingly, we need to see how material should be selected in which kind of material
should be selected for successful performance in a given application. Design and design
actually helps to find out the suitable size and shape, but what parameters to be used for
determining that size, and shape that will depend upon the expected failure or expected
failure mechanism, whether it will fail by tile brittle creep ductile brittle fracture creep
fracture creep fatigue corrosion or v r. So, coming to this one unlike if the component say
if the component is expected to fail by the plastic deformation, at room temperature, then
will be considering the yield strength.

(Refer Slide Time: 28:22)

If the component is expected to fill the deformation, by at high temperature then we need
to consider the creep rate or the creep behavior of the material.

Similarly, if the failure of the component is expected to cover expected to occur under
the over load fracture fluctuating load facture or impact load conditions, then we have to
consider the impact sorry ultimate strength or endurance limit or and endurance strength
the impact strength of the material. So, these are so, as per the case we have to consider
the suitable kind of the parameters which should be used for selection of the suitable
material. Now coming to the few failure mechanisms and the parameters which is to be
considered, for and these this table basically shows the parameters that needs to be that
should be considered for a selection of the suitable material and suitable design.

(Refer Slide Time: 29:19)

So, if the if the ductile fracture is taking place, if the if the estimated failure mechanism
is the ductile fracture, and the yield strength as per the type of load it may be tension
compression, then if the expected failure mechanism failure mechanism is the brittle
fracture, then we need to consider the fracture toughness notch toughness ductility
ductile to brittle transition temperature so, that the material can perform on it is design
can be based on these parameters.

And so, that it can perform the intended function successfully in order to avoid any
premature failure. So, if the failure has taken place then we need to see what kind of
force what would have been the mechanism of the failure and whether the material had
these characteristics or not to register those service conditions. So, this list can also be
used to see what kind of characteristics a metal should have to perform under given
service conditions. So, after the failure, we can easily identify the kind of failure
mechanism which would be there for a metal, and if the material is material which has
failed is having those characteristics or not that can be used to identify if the design was
proper or the design was deficient. So, the fatigue fracture like if the design is to be
based on the fatigue.

If the expected failure mechanism is a fatigue then the endurance limit and the fatigue
strength with this stress raiser, and the hardness should be considered thermal fatigue is
the probable case for the failure, then the ductility and the peek plastic strain under the
given temperature variation should be considered as a creep is the foreseeable
mechanism, then the creep rate at a given temperature needs to be considered. And for
the plastic deformation if that the change in dimension of the component under the given
service conditions is a possible way by which the component can fail.

Then we need to consider the yield strength or at high temperature it is the creep
condition creep. And if the component is subjected to the tensile stresses in crosier
enrolment, then we need to consider the k one ssc which is the stress critical, stress
concentration factor under the corrosive environmental conditions. And the corrosion
resistance to the spes environment also needs to be considered.

So now, will I will conclude this presentation. In this presentation, I have talked about
the how upgrading a part to the newer applications can lead to the failure. And also, I
have talked about how the in appropriate design criteria, and the inappropriate, improper
stresses can lead to the failure.

Thank you for your attention.